System for Identifying and Duplicating Master Keys

ABSTRACT

A system for duplicating a master key includes a clamping mechanism for receiving and positioning a master key. The master key defines a major key axis and an intermediate key axis along which a key blade variably extends. The key blade has an upper surface and a minor key axis along a key thickness. A mechanical measurement device includes a probe that deflects along the intermediate key axis during a measurement process. A movement mechanism imparts relative motion along the major key axis between the mechanical measurement device and the master key. The mechanical probe follows the upper surface of the key blade. The mechanical measurement device generates a signal indicative of the deflection of the probe. A processor receives the signal and generates information usable for defining the machining of a duplicate key.

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation of U.S. application Ser. No. 15/191,101, filed onJun. 23, 2016, which claims the benefit of US Provisional ApplicationNo. 62/185,081, filed Jun. 26, 2015, hereby incorporated herein byreference.

TECHNICAL FIELD

This is directed to the field of key duplication, and more specificallyto the field of apparatuses and methods of automatically analyzingmaster keys in an automated and very accurate manner.

BACKGROUND

Various key duplication systems exist for receiving and duplicating amaster key. More recent key duplication systems can be automated. Suchsystems have to perform certain functions.

First, a proper key blank needs to be selected. A typical key blank ischaracterized factors such as a keyway which is defined by a geometry ofa cross-section of a key. An improperly selected key blank will resultin an attempted duplicate that cannot be inserted into a lock. Somesystems rely on a user to select the proper key blank. This may lead tohuman error. There is a desire to provide highly reliable automated keyblank selection.

Second, the master key needs to be analyzed or traced to obtain thecorrect “bitting pattern” which defines the shape of a master key blade.An improper determination of the bitting pattern will result in the keynot opening a particular lock.

There is an ongoing need to improve the reliability and accuracy ofsystems that select key blanks and determine bitting patterns for thepurpose of key duplication.

SUMMARY

A system and method of the present disclosure provides an accurate andreliable system and method for analyzing a master key. Analyzing themaster key includes identifying an optimal key blank and the determininga bitting pattern to be machined into the identified key blank. Themaster key geometrically defines three mutually orthogonal axesincluding a major key axis which is the longest axis of the master key,an intermediate key axis along which a key blade variably extends, and aminor key axis along a key thickness. The variable extent of the keyblade defines a bitting of the master key. The key blade includes anupper surface having a surface profile that varies along the major keyaxis and defines the bitting of the master key.

In one aspect of the disclosure a key duplication system includesvarious major components including the following: (1) a clampingmechanism for receiving and positioning a master key whereby the masterkey defines a major key axis, an intermediate key axis along which a keyblade variably extends, the key blade having an upper surface, and aminor key axis along a key thickness; (2) a mechanical measurementdevice including a probe that deflects along the intermediate key axisduring a measurement process; (3) a movement mechanism that impartsrelative motion along the major key axis between the mechanicalmeasurement device and the master key whereby the mechanical probefollows the upper surface of the key blade and the mechanicalmeasurement device generates a signal indicative of the deflection ofthe probe; and (4) a processor that receives the signal and generatesinformation usable for defining the machining of a duplicate key.

In one implementation the clamping mechanism holds the master key in afixed stationary location. Thus the relative motion is a result ofmotion of the mechanical measurement device along the major key axis.

In another implementation the movement mechanism is a moveable stageconfigured to move linearly along the major key axis. The mechanicalmeasurement device is affixed to the moveable stage whereby linearmotion of the moveable stage imparts the relative motion.

In a further implementation the movement mechanism is a moveable stageconfigured to move linearly along the major key axis. The mechanicalmeasurement device is affixed to the moveable stage whereby linearmotion of the moveable stage imparts the relative motion. A camera isattached to the moveable stage and configured to receive an image of adistal end of the master key. The system further includes a computercoupled to the processor and to the camera. The computer utilizesinformation from the camera to align the movement mechanism along themajor key axis.

In yet another implementation the movement mechanism is a moveable stageconfigured to move linearly along the major key axis. The mechanicalmeasurement device is affixed to the moveable stage whereby linearmotion of the moveable stage imparts the relative motion. A camera isattached to the moveable stage and configured to receive an image of adistal end of the master key. The system further includes a computercoupled to the processor and to the camera. The computer receivesinformation from the processor originating from the mechanicalmeasurement device and utilizes this information to align the camera toa distal end of the master key along the major key axis.

In a further implementation the mechanical measurement device includes alinear variable differential transformer (LVDT). An LVDT is a type ofelectrical transformer used to measure linear displacement and position.The term LVDT sometimes also is referred to as a linear variabledisplacement transducer or a linear variable displacement transformer.

In another implementation the mechanical measurement device isstationary and the relative motion is imparted by motion of the clampingmechanism along the major key axis.

In another aspect of the disclosure a method for duplicating a masterkey includes: (1) receiving and clamping a master key defining a majorkey axis, an intermediate key axis along which a key blade variablyextends, and a minor key axis that defines a key thickness; (2)imparting relative motion along the major key axis between a mechanicalmeasurement device with a mechanical probe and the master key wherebythe mechanical probe moves along the intermediate key axis whilefollowing an upper surface of the key blade; (3) the mechanicalmeasurement device generating a signal indicative of the extension ofthe key blade along the intermediate key axis; and (4) a processorreceiving the signal and generating information usable for defining themachining of a duplicate key.

In one implementation, receiving and clamping the master key includesaffixing the master key in a stationary configuration. The relativemotion is a result of motion of the mechanical measurement device alongthe major key axis.

In another implementation, the relative motion is imparted by a moveablestage that supports and transports the mechanical measurement devicewhile moving along the major key axis.

In a further implementation a camera is attached to the moveable stage.In one embodiment the method includes the camera detecting a distal endof the master key to align the mechanical probe to the key blade alongthe major key axis.

In yet another implementation, a camera is attached to the moveablestage. In one embodiment the method includes computing an alignment ofthe camera to a distal end of the master key based upon analyzinginformation from the processor.

In a further aspect of the disclosure a key duplication system includesvarious major components including the following: (1) a clampingmechanism for receiving and positioning a master key whereby the masterkey defines a major key axis, an intermediate key axis along which a keyblade variably extends, the key blade defining an upper surface, and aminor key axis along a key thickness; (2) an image capture system forgenerating image information indicative of a keyway geometry for themaster key; (3) a mechanical measurement system for mechanicallyprofiling the key blade and generating bitting information for themaster key; and (4) a computer that receives information generated bythe image capture system and the mechanical measurement mechanism, thecomputer computes bitting information based upon the information fromthe mechanical measurement mechanism, the computer selects a proper keyblank based at least upon the image information. In one embodiment thecomputer selects a proper key blank based upon the image information andthe bitting information. In another embodiment the computer controlsmachining of the selected key blank based upon the bitting information.

In one implementation the mechanical measurement system includes amechanical measurement device including a probe that deflects along theintermediate key axis. In one embodiment the mechanical measurementsystem includes a movement mechanism that transports the mechanicalmeasurement device along the major key axis whereby the probe followsthe upper surface of the key blade, the information received by thecomputer from the mechanical measurement system is based upon thedeflection of the probe over the upper surface.

In another implementation the computer aligns the mechanical measurementsystem to the master key based upon the information received from theimage capture system.

In a further implementation the computer aligns the image capture systemto a distal end of the master key based upon the information receivedfrom the mechanical measurement system.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 A is an isometric view of an exemplary master key.

FIG. 1B is a side view of an exemplary master key.

FIG. 1C is a cross sectional view of an exemplary master keyillustrating the keyway.

FIG. 2 is a schematic plan or top view of certain components of a system20 utilized for analyzing and duplicating a master key.

FIG. 3 is a side view depicting a mechanical measurement device scanningalong a major key axis of a master key. During the scanning, a probefollows an upper surface of a key blade.

FIG. 4 is an electrical block diagram of an exemplary system foranalyzing and duplicating a master key.

FIG. 5 is a flowchart representation of an exemplary embodiment of amethod for duplicating a master key.

FIG. 6 is a flowchart representation of an exemplary alternativeembodiment of a method for duplicating a master key.

DETAILED DESCRIPTION

FIGS. 1A, 1B, and 1C are isometric, side, and cross sectional views ofan exemplary master key 2 to be analyzed for purposes of duplication.According to this description, a master key 2 is any key that a user orcustomer desires to duplicate such as a house key, a key to a storageunit, a key to automobile, or any other key that mechanically opens orcloses a lock.

To illustrate master key 2, three mutually orthogonal axes X, Y, and Zare defined. Minor key axis X is defined along the thickness of masterkey 2. Major key axis Y is defined along the longest axis of master key2. Head 4 and distal end 6 of master key 2 are disposed along major keyaxis Y. Intermediate key axis Z is the defined as the direction alongwhich key blade 8 variably extends.

Master key 2 is uniquely defined by various factors including a (1)keyway 10, and (2) bittings or teeth formed into key blade 8. Keyway 10is defined by a cross section 10 of master key 2. The keyway 10 hasfeatures such as channels 12 and ridges 14 that allow the master key 2to slide into a particular lock. The channels 12 and ridges 14 define avariable extent of a portion of key blade 8 along minor key axis X.

Key blade 8 extends variably along intermediate axis Z. The variableextent of key blade 8 defines features such as key teeth 16. Thevariable extent of key blade 8 defines the bitting of master key 2. Thebitting of master key 2 determines which specific lock master key 2 canunlock and lock.

Key blade 8 has an upper surface 34 (FIG. 3) whose dimension Z(surface)along the intermediate key axis Z varies with a position along the majorkey axis Y. This variation can be referred to as the “surface profile”of upper surface 34 or of key blade 8. The surface profile defines thebitting of master key 2.

FIG. 2 depicts a schematic representation of an exemplary system 20 foranalyzing a master key 2 to be duplicated. System 20 utilizes amechanical measurement mechanism 22 in combination with an image capturesystem 24 in order to analyze master key 2. Analyzing master key 2 hastwo parts—(1) identifying a proper key blank and (2) determining thebitting for master key 2. In an exemplary embodiment the system 20utilizes both the mechanical measurement mechanism 22 and the imagecapture system 24 in order to determine the proper key blank for masterkey 2. System 20 uses the mechanical measurement system 22 to determinethe bitting for master key 2.

System 20 includes a clamping mechanism 26 for receiving and clampingmaster key 2. In an exemplary embodiment clamping mechanism 26 isstationary during the use of system 20.

FIG. 3 is a side view schematic illustration that is depicting a masterkey 2 whose bitting is being measured by mechanical measurement system22. Mechanical measurement system 22 is configured to measure thebitting on master key 2 utilizing movement along two axes. The two axesinclude major key axis Y and intermediate key axis Z. Mechanicalmeasurement system 22 includes a mechanical measurement device 28 thatis mounted to a movement mechanism 30.

Mechanical measurement device 28 includes a probe 32 that is configuredto deflect along the intermediate key axis Y. As the probe 32 isdeflected, mechanical measurement device 28 generates a signalindicative of a magnitude of the deflection. In one embodiment,mechanical measurement device 28 includes a linear variable differentialtransformer (LVDT) that is an electrical transformer that measureslinear displacement of the probe 32.

In one embodiment mechanical measurement device 28 is translated alongthe major key axis Y during measurement of master key 2 bitting. Duringmeasurement the probe 32 follows upper surface 34 of key blade 8. Thusmeasurement probe 32 moves along two dimensions including major key axisY and intermediate key axis Z. As measurement probe 32 moves itgenerates an output signal that is indicative of its movement ordisplacement along intermediate key axis Z versus time as it translatesalong major key axis Y. This output signal is used to determine thebitting of master key 2.

Referring back to FIG. 2, the image capture system 24 includes lightsources 36 and a camera 38. In an exemplary embodiment light sources 36are light emitting diodes (LEDs) 36. Light sources 36 are positioned toilluminate a surface of the distal end 6 of master key 2. Camera 38receives light generally reflected in the +Y direction from distal end 6to provide an image that represents the keyway 10 (see FIG. 1C). In oneembodiment light sources 36 and camera 38 are mounted to moveable stage40. In another embodiment light sources 36 are fixed and camera 38 ismounted to moveable stage 40.

In an exemplary embodiment system 20 processes the image from camera 38to generate information characterizing or defining keyway 10 (FIG. 1C).From this information system 20 may determine a proper key blank forduplicating master key 2. In a preferred embodiment system 20 utilizesthe information characterizing keyway 10 and the bitting of master key 2to determine the proper key blank.

In an alternative embodiment the mechanical measurement device 28 isstationary along major key axis Y while clamping mechanism 26 translatesalong major key axis Y during a process of measuring bitting of masterkey 2. In this exemplary embodiment the probe 32 only moves alongintermediate key axis Z during a measurement of master key 2 bitting.Although probe 32 only moves along intermediate key axis Z it stillfollows upper surface 34 (FIG. 3) of key blade 8 as the master key 2 istranslated along major key axis Y. In this alternative embodiment probe32 generates an output signal that is indicative of its movement ordisplacement along intermediate key axis Z versus time. This outputsignal is used to determine the bitting of master key 2.

FIG. 4 depicts an exemplary electrical block diagram of circuitry andvarious components of the system 20 previously described with respect toFIGS. 2 and 3. It is to be understood that certain components of FIG. 4have interconnections that for purposes of simplicity are notillustrated. System 20 includes a main PCBA 50 (printed circuit boardassembly) that is interconnected to various system components and tocomputer 52. Communication between PCBA 50 and computer 50 isaccomplished via a universal serial bus (USB) port 54. Computer 52 sendscontrol commands to PCBA 50 and receives data from PCBA 50 that isusable to determine a proper key blank and for machining key blade 8 toprovide a duplicate of master key 2.

PCBA 50 includes a LVDT driver 58 that generates a signal based upon thedeflection of probe 32. The signal from LVDT driver 58 is digitized byA/D converter 55 and then passed to microcontroller 56. Microcontroller56 processes the signal and sends information to computer 52 that isindicative of the height of key blade 8 along intermediate key bladeaxis Z versus time or displacement via the USB port 54.

PCBA 50 includes a clamp driver 60 for operating clamping mechanism 26(FIG. 2). In the illustrative embodiment clamping mechanism 26 includesvertical clamp 26V and horizontal clamp 26H for clamping master key 2.

PCBA 50 includes a motor driver 62 for controlling a stepper motor 64for translating movement mechanism 30 along major key axis Y. Motordriver receives positional feedback from encoder 66.

PCBA 50 includes an LED driver 68 for driving LEDs 36 for illuminatingthe distal end 6 of master key 2. Camera 38 provides information tocomputer 52 that is indicative of an end image received from distal end6 of master key 2.

FIG. 5 is a flowchart depicting an exemplary process 100 for providing aduplicate of master key 2. For this exemplary embodiment the system 20described with respect to FIGS. 2, 3, and 4 is utilized.

According to initial condition 102 the mechanical measurement device 28is at a home position which is as far to the −Y position as possible.According to step 104, a master key 2 is received in clamping mechanism26 and the process 100 is started. Also according to step 104 the masterkey 2 is clamped by clamping mechanism 26.

According to step 106 the probe 32 is lowered along intermediate keyaxis Z and into engagement with the upper surface 34 of key blade 8.According to step 108 the mechanical measurement device 28 is movedalong major key axis Y in the +Y direction from near the head 4 towardthe distal end 6 of master key 2. As the mechanical measurement device28 moves in the +Y direction the probe 32 follows the profile of uppersurface 34 of key blade 8 as is illustrated in FIG. 3. Thus probe 32deflects along the intermediate key axis Z in response to variations inthe Z coordinate of upper surface 34 of key blade 8. The mechanicalmeasurement device 28 generates a signal indicative of the probe 32deflection. The signal is digitized and sent to the microcontroller 56(FIG. 4). The microcontroller 56 processes the signal and sendsinformation to computer 52 indicative of the bitting of master key 2.

According to step 110 the mechanical measurement device 28 passes thedistal end 6 of the master key 2. As the distal end 6 is passed theprobe 32 remains at a maximum extension in the −Z direction. System 20utilizes this information to determine the Y coordinate of the distalend. This allows system 20 to determine an imaging position for camera38.

According to step 112 the system 20 uses the Y coordinate of distal end6 to determine the proper positioning of camera 38 to focus on thedistal end 6 of master key 2. Also according to step 112 the camera 38is moved into the position for focusing on distal end 6.

According to step 114 camera 38 captures an image of the distal end 6 ofmaster key 2. According to step 116 the image of distal end 6 and thebitting information (captured in step 108) are used to determine andenable a selection of a proper key blank. According to step 118 theselected key blank is machined using the bitting determined from step108.

According to step 120 the master key 2 is released and removed fromclamping mechanism 26. Also as part of step 120 the mechanicalmeasurement device 28 is moved in the −Y direction and back to the homeposition according to initial condition 102.

FIG. 6 is a flowchart depicting an alternative exemplary process 150 formachining a duplicate of master key 2. For process 150 the system 20described with respect to FIGS. 2, 3, and 4 is utilized. Also for thisexemplary embodiment the mechanical measurement device 28 and camera 38are mounted to moveable stage 40.

According to step 152 the moveable stage 40 is in a retracted (+Y)position along major key axis Y so that measurement device 28 is somedistance from distal end 6 along +Y. According to step 154, a master key2 is received in clamping mechanism 26 and the process 150 is started.Also according to step 154 the master key 2 is clamped by clampingmechanism 26.

According to step 156 the moveable stage is 40 translated in the −Ydirection along major key axis Y. During step 156 camera 38 andassociated software searches for the distal end 6 of master key 2. Morespecifically system 20 is searching for a Y position of moveable stage40 at which camera 38 is able to focus on a portion of distal end 6.According to step 158 system 20 determines this Y position and moves tothat position whereby camera 38 can focus on a portion of distal end 6.

According to step 160 camera 38 captures an image of the distal end 6 ofmaster key 2. As a consequence of determining the Y position forfocusing, system 20 can also compute the a Y position for the moveablestage 40 at which mechanical profiling of key blade 8 can begin.According to step 162 movable stage moves in Y whereby the mechanicalmeasurement device is in a proper start position for profiling key blade8. According to step 164 probe 32 moves down and engages upper surface34 key blade 8.

According to step 166 the moveable stage 40 translates in the −Ydirection whereby probe 32 follows the upper surface 34 of key blade 8.In following upper surface 34 the probe deflects along intermediate keyaxis Z. In response the mechanical measurement device 28 generates asignal indicative of the deflection of probe 32 which is digitized andthen transmitted to the microcontroller 56 (FIG. 4). The microcontroller56 processes the signal and sends information to computer 52 indicativeof the bitting of master key 2.

According to step 168, the system 20 utilizes the image from step 160and the bitting information to identify and select a proper key blankfor duplicating master key 2. According to step 170, the system 20utilizes the bitting information from step 166 to machine a duplicatekey from the selected key blank.

According to step 172 the master key 2 is released and removed fromclamping mechanism 26. Also as part of step 172 the mechanicalmeasurement device 28 is moved in the +Y direction and back to the homeposition according to initial condition 152.

The specific embodiments and applications thereof described above arefor illustrative purposes only and do not preclude modifications andvariations encompassed by the scope of the following claims.

1. A system for duplicating a master key comprising: a clamping mechanism for receiving and positioning a master key whereby the master key defines a major key axis, an intermediate key axis along which a key blade variably extends, the key blade having an upper surface, and a minor key axis along a key thickness; a measurement device configured to generate a signal indicative of variations in the master key along the intermediate key axis during a measurement process; a movement mechanism that imparts relative motion along the major key axis between the measurement device and the master key during the measurement process; one or more processors that receive the signal and generate information usable for defining the machining of a duplicate key; and a camera attached to the movement mechanism and configured to receive an image of the distal end of the master key, wherein the one or more processors utilize information from the camera to align the movement mechanism along the major key axis.
 2. The system of claim 1 wherein the clamping mechanism holds the master key in a fixed location whereby the relative motion is a result of motion of the measurement device along the major key axis.
 3. The system of claim 1 wherein the movement mechanism is a moveable stage configured to move linearly along the major key axis, the measurement device is affixed to the moveable stage whereby linear motion of the moveable stage imparts the relative motion.
 4. The system of claim 1, wherein the one or more processors are further configured to utilize the information to align the camera to a distal end of the master key along the major key axis.
 5. The system of claim 1 wherein the mechanical measurement device includes a linear variable differential transformer (LVDT).
 6. The system of claim 1 wherein the mechanical measurement device is stationary and the relative motion is imparted by motion of the clamping mechanism along the major key axis.
 7. A method of duplicating a master key comprising: receiving and clamping a master key defining a major key axis, an intermediate key axis along which a key blade variably extends, and a minor key axis that defines a key thickness; detecting a distal end of the master key using a camera to align a measurement device to the key blade along the major key axis; imparting relative motion along the major key axis between the measurement device and the master key; the measurement device generating a signal indicative of variations in the key blade along the intermediate key axis; and using the signal to generate information usable for defining the machining of a duplicate key.
 8. The method of claim 7 wherein the master key remains stationary in a clamped state while the relative motion results from the measurement device moving along the major key axis.
 9. The method of claim 7 wherein the relative motion is imparted by a moveable stage that supports and transports the measurement device while moving along the major key axis.
 10. The method of claim 9 wherein the camera is attached to the moveable stage.
 11. The method of claim 7 further comprising computing an alignment of the camera to a distal end of the master key based upon analyzing the information from the processor.
 12. A system for duplicating a master key comprising: a clamping mechanism for receiving and positioning a master key whereby the master key defines a major key axis, an intermediate key axis along which a key blade variably extends, the key blade defining an upper surface, and a minor key axis along a key thickness; an image capture system for generating image information indicative of a keyway geometry for the master key; a measurement system for profiling the key blade and generating bitting information for the master key; a computer that receives information generated by the image capture system and the measurement mechanism, the computer being configured to (a) align the measurement mechanism to the master key based upon information received from the image capture system, (b) compute bitting information based upon the information from the measurement mechanism, and (c) select a proper key blank based at least upon the image information.
 13. The system of claim 12 wherein the measurement system includes a mechanical measurement device including a probe that deflects along the intermediate key axis.
 14. The system of claim 12 wherein the measurement system includes a movement mechanism that transports the measurement system along the major key axis.
 15. The system of claim 12 wherein the computer selects a proper key blank based upon the image information and the bitting information.
 16. The system of claim 12 wherein the computer controls machining of the selected key blank based upon the bitting information. 